Echotel 961/962 Line Powered BE51-645

ECHOTEL® 961/962
LINE POWERED
Installation and Operating Manual
Ultrasonic
Single and
Dual Point
Level Switches
Model 961
Model 962
®
UNPACKING
Unpack the instrument carefully. Make sure all components
have been removed from the foam protection. Inspect all
components for damage. Report any concealed damage to
the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number
to be sure it agrees with the packing slip and purchase
order. Check and record the serial number for future reference when ordering parts.
0038
0344
Nameplate:
- part number
- serial n°
These units are in compliance with:
1. The EMC directive 2004/108/EC. The units have been tested to
EN 61326: 1997 + A1 + A2.
2. Directive 94/9/EC for equipment or protective system intended for
use in potentially explosive atmospheres. EC-type examination certificate number ISSeP06ATEX008 - flameproof enclosure.
3. The PED Directive 97/23/EC (pressure equipment directive). Safety
accessories per category IV module H1.
MOUNTING
High alarm
High high alarm
Filling line
Pump control
High alarm
High alarm
Auto fill or
empty pump control
Pump protection
Low alarm
Pump
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Welded flange
Tri-Clamp®
DIN 11851
Varivent®
WIRING
Echotel® 961 electronics
Malfunction
SPDT relay
Echotel® 962 electronics
1 x DPDT (961)
2 x SPDT (962)
relay(s)
Ground
Input power
NC
C
NO
NC
Hi PC
Lo LC
NC
C
NO
MALF RELAY
Hi I
Lo J
NC
C
MALF
TEST
NO
NC
C
NO
WET
MALF
FAULT LEVEL
L1
C
NO
C
NO
L1
L2
TIME
DELAY
LEVEL
TEST
MODEL 962
102 to 265 V AC
L2
L1
TIME
DELAY
L2
18 to 32 V DC
LEVEL
TEST
MODEL 961
NC
UPPER
LOWER
MALF
MALF
UPPER
TEST
FAULT
LOWER
MALF RELAY
+
-
HAZARDOUS AREA
SAFE AREA
NC
Malfunction relay
Process relay(s)
C
NO
NC
C
NO
Process relay(s)
NC
C
NO
Important: Connect the unit to the ground for avoiding earth potential drifts. Use the green internal
grounding screw
USER INTERFACE
Echotel® 961
NC
C
NO
MALF RELAY
Hi I
Lo J
Testing
malfunction
relay
NC
MALF
TEST
Fault
red
LED
C
Echotel® 962
NO
NC
C
NO
WET
MALF
FAULT LEVEL
Alarm
status
yellow
LED
NC
L2
TIME
DELAY
LEVEL
TEST
MODEL 961
Wet
yellow
LED
L1
C
NO
MALF RELAY
Testing
DPDT
process
relay
Malfunction
green LED
Note: in normal operation «Fault» is OFF / «MALF» is ON
in malfunction condition: «Fault» is ON / «MALF» is OFF
NC
C
NO
NC
C
NO
L1
LOWER
UPPER
MALF
MALF
UPPER
TEST
FAULT
LOWER
Hi PC
Lo LC
Fault
red
LED
MODEL 962
Malfunction
green LED
L2
TIME
DELAY
LEVEL
TEST
Lower gap
alarm
yellow
LED
Upper gap
alarm
yellow LED
3
SET UP AND FUNCTIONS
Set up
High – Low Level Failsafe selection:
In «Hi» position, the process relay will de-energize (report alarm) when the transducer is wet.
In «Lo» position, the process relay will de-energize (report alarm) when the transducer is dry.
Fault selection:
The Echotel 961 is equipped with a malfunction relay separate from the 5A DPDT process relay. The separate or joined operation of both relays can be selected :
I = in case of a malfunction, only the malfunction relay will de-energize. The process relay will only de-energize in case of a
process alarm
J = in case of a malfunction, both the malfunction relay and the process relay will de-energize
The Echotel 962 is equipped with a malfunction relay separate from the two 5A SPDT process relays. In case of a malfunction,
both the malfunction relay and the process relays will de-energize. The operation of the two process relays can be selected:
LC (level control) = the two relays operate independent and will be de-energized when the corresponding tranducer gap is
immerged/dry (following Hi/Lo setting)
PC (pump control) = the two relays operate in a latched mode, allowing to perform an automatic fill or drain pump control function in between the 2 transducer gaps. Consult below tables for proper indication and function.
Time delay setting:
Turning the potentiometer clockwise will increase the time delay from 0,5 s to 45 s. Time delay is typically used where turbulence, boiling or splashing can cause false level alarms.
961 - Relay/ LED Indication:
When «WET» (wet LED): OFF = transducer gap is dry / ON = transducer gap is immerged
When «LEVEL» (level LED): ON = relay is energized / OFF = relay de-energized
Echotel 961: Relay/LED indication
Mode
«Hi»
High level
failsafe
«Lo»
Low level
failsafe
4
Level
Process
relay
« LEVEL» LED
(relay - yellow)
« WET» LED
(gap - yellow)
Energized
ON
OFF
De-energized
OFF
ON
Energized
ON
ON
De-energized
OFF
OFF
Error LED indication
Fault (red)
Malfunction
(green)
OFF =
Normal
operation
ON =
Normal
operation
ON =
Malfunction
See
troubleshooting
for malfunction
identification
OFF =
Malfunction
See
troubleshooting
for malfunction
identification
SET UP AND FUNCTIONS
Echotel 962 as level control «LC»: Relay/LED indication
Relay # 1 = lower gap – Relay # 2 = upper gap
Level
Mode
«Hi»
High level
failsafe
«Lo»
Low level
failsafe
«Hi»
High level
failsafe
«Lo»
Low level
failsafe
«Hi»
High level
failsafe
«Lo»
Low level
failsafe
Process
relay
Lower LED
Upper LED
# 1 & 2:
Energized
ON
ON
# 1 & 2:
De-energized
OFF
OFF
OFF
ON
ON
OFF
De-energized
OFF
OFF
Energized
ON
ON
# 1:
De-energized
# 2:
Energized
# 1:
Energized
# 2:
De-energized
Error LED indication
Malfunction
Fault (red)
(green)
OFF =
Normal
operation
ON =
Malfunction
See
troubleshooting
for malfunction
identification
ON =
Normal
operation
OFF =
Malfunction
See
troubleshooting
for malfunction
identification
Echotel 962 pump control «PC»: Relay/LED indication
High Level Failsafe (Hi) = auto empty mode
Low Level Failsafe (Lo) = auto fill mode
Level
Mode
Process
relay
Lower LED
Upper LED
«Hi»
High level
failsafe
Energized
ON
ON
«Hi»
High level
failsafe
De-energized
OFF
OFF
De-energized
OFF
OFF
Energized
ON
ON
De-energized
OFF
OFF
Energized
ON
ON
Energized
ON
ON
De-energized
OFF
OFF
«Lo»
Low level
failsafe
«Lo»
Low level
failsafe
«Hi»
High level
failsafe
«Lo»
Low level
failsafe
«Hi»
High level
failsafe
«Lo»
Low level
failsafe
Error LED indication
Malfunction
Fault (red)
(green)
OFF =
Normal
operation
ON =
Malfunction
ON =
Normal
operation
OFF =
Malfunction
See
See
troubleshooting troubleshooting
for malfunction for malfunction
identification
identification
5
MAINTENANCE
Manual Testing
Level Test: (process relay(s)):
Pressing the “Level Test” pushbutton, will manually test the process relays and connected actuators/indicators. The level test
forces the relay(s) to change from a de-energized to an energized status and vice versa. The LEDʼs will be ON/OFF corresponding (see tables in the configuration section). The time delay setting is not active during testing.
Malfunction Test (malfunction relay):
Pressing the “Malfunction Test” pushbutton for min 2 s, will manually test the malfunction relay and connected actuators/indicators. The malfunction test simulates a circuit failure and forces all relays to de-energize. The «MALF» LED will turn
OFF and the «FAULT» LED ON. The time delay setting is not active during testing.
Troubleshooting
Problem
Action/Indication
No output signal
No LEDʼs are ON
No change in output between
wet gap / dry gap
Gap may be plugged by
solids / dense foam
Chattering output
Excessive aeration / Turbulence
Fault LED is ON
Gap is out of reach of liquid
A system fault has been detected
Press «LEVEL TEST» test pushbutton
to identify the problem:
*
--- *
: 1 flash
** --- ** : 2 flashes
*** --- *** : 3 flashes
6
Solution
Check wiring / input power
Check for malfunction (962). See below
Clean the transducer
Check mounting section on page 2 and
relocate the unit or check blocking
valves.
Introduce a time delay
Check input power
Relocate the switch
Check input power
Check wiring between transducer and
electronics or replace transducer.
Check wiring between transducer and
electronics or replace transducer.
Replace electronics
The unit senses excessive noise
interference. Check shield connection or
eliminate interference from a walkietalkie, radio or other nearby source
REPLACEMENT PARTS
Replacing electronics/transducer
Echotel electronics can be removed in the field under process conditions. Follow below steps to exchange electronics/transducer:
Note: Adjust set up of the replacing electronics following the settings of the old electronics (see configuration section)
1.
2.
3.
4.
5.
6.
Disconnect power before removing the housing cover
Remove power/output wires (a)
(Skip step 3 if hygienic housing.) Click out the protection cap of the electronics (b)
Remove the 2 bracket screws and slide out electronics (c)
Remove the transducer wires (see Wiring section) (d)
Re-assemble following the same procedure in opposite way. Make sure that the tip on the bracket of the electronic block is
seated properly in the corresponding recess in the housing base - (e)
Replacement parts
Partn°:
Digit in partn°:
X 1 2 3
4 5 6 7
8 9 10
1
X = product with a specific customer requirement
Serial n°:
See nameplate, always provide complete partn° and
serial n° when ordering spares.
No.
1
2
3
4
Description
Cast aluminium cover (digit 10 = 0 or 1)
Blind
With window
Cast stainless steel cover (digit 10 = 2 or 3)
Blind
Deep drawn stainless steel cover
(digit 10 = 4 or 5)
Blind
With window
“O”-Ring
digit 10 = 0, 1, 2 or 3
digit 10 = 4 or 5
Electronic module for industrial
housing (digit 10 = 0, 1, 2 or 3)
961 – AC power
961 – DC power
962 – AC power
962 – DC power
Electronic module for hygienic
housing (digit 10 = 4 or 5)
961 – AC power
961 – DC power
962 – AC power
962 – DC power
Transducer
Part Number
004-9192-004
036-4410-010
004-9192-023
036-5702-003
036-5702-002
2
b
3
c
a
3
3
d
3
e
012-2201-237
012-2201-155
089-7259-001
089-7259-002
089-7258-001
089-7258-002
089-7256-001
089-7256-002
089-7257-001
089-7257-002
consult factory
4
7
MODEL IDENTIFICATION
A complete measuring system consists of:
1. Echotel® electronics
2. Echotel® transducer
1. Code for Echotel® electronics
BASIC MODEL NUMBER
9 6 1
9 6 2
Echotel 961 electronics for single setpoint 9M1 transducers
Echotel 962 electronics for dual setpoint 9M2 transducers
INPUT POWER
2 D A
7 D A
18 - 32 V DC line powered electronics with 5 A gold flash relay(s) output
102 - 265 V AC line powered electronics with 5 A gold flash relay(s) output
ACCESSORIES
0
1
Blind housing cover
Housing cover with glass window (for aluminium housings only)
MOUNTING
0
Integral mount electronics
APPROVALS
C
3
7
ATEX II 1/2 G EEx d IIC T6, flameproof enclosure - except deep drawn SST housing
Weatherproof
- except deep drawn SST housing
Weatherproof
- deep drawn SST housing
HOUSING / CABLE ENTRY
1
0
3
2
5
4
9 6
8
D A
0
Cast aluminium housing with M20 x 1,5 cable entry (2 entries – one plugged)
Cast aluminium housing with 3/4" NPT cable entry (2 entries – one plugged)
Cast stainless steel with M20 x 1,5 cable entry (2 entries – one plugged)
Cast stainless steel with 3/4" NPT cable entry (2 entries – one plugged)
Deep drawn 304 stainless steel with M20 x 1,5 cable entry (2 entries – one plugged)
Deep drawn 304 stainless steel with 1/2"NPT cable entry (2 entries – one plugged)
complete code for Echotel® electronics
X = product with a specific customer requirement
MODEL IDENTIFICATION
2. Code for Echotel® transducer
BASIC MODEL NUMBER
9 M 1
9 M 2
Echotel® 961 transducer with single setpoint
Echotel® 962 transducer with dual setpoints
TRANSDUCER MATERIALS (use only metal transducers for hazardous area)
A
B
C
P
R
S
316/316L (1.4401/1.4404) stainless steel
Hastelloy® C (2.4819) – only available with 9M1
Monel® (2.4360) – only available with 9M1
CPVC
Kynar® (PVDF) – only available with 9M1
316/316L (1.4401/1.4404) stainless steel with 0,5 µm Ra (20 Ra) surface finish
PROCESS CONNECTION
Threaded (plastic transducers are only available with 3/4" NPT connection)
1 1
3/4" NPT
2 1
1" NPT
2 2
1" BSP (G 1")
ANSI Flanges for metal transducers
2 3
1"
150 lbs ANSI RF
2 4
1"
300 lbs ANSI RF
2 5
1"
600 lbs ANSI RF
3 3
1 1/2" 150 lbs ANSI RF
3 4
1 1/2" 300 lbs ANSI RF
3 5
1 1/2" 600 lbs ANSI RF
4 3
2"
150 lbs ANSI RF
4 4
2"
300 lbs ANSI RF
4 5
2"
600 lbs ANSI RF
ANSI Flanges for plastic transducers➀
2 3
3 3
4 3
1"
150 lbs ANSI RF➁
1 1/2" 150 lbs ANSI RF➁
2"
150 lbs ANSI RF➁
EN (DIN) Flanges for plastic transducers➀
B A
C A
D A
DN 25 PN 16
DN 40 PN 16
DN 50 PN 16
B S
C S
D S
DN 25 DIN 11851
DN 40 DIN 11851
DN 50 DIN 11851
➀ CPVC flanges for CPVC transducers, Kynar® cladded SST flanges for Kynar® transducers
➁ FF (flat face) flanges for CPVC transducers
Hygienic
3 T
4 T
V V
EN (DIN) Flanges for metal transducers
B B DN 25 PN 16/25/40 EN 1092-1 Type A
B C DN 25 PN 63/100
EN 1092-1 Type B2
C B DN 40 PN 16/25/40 EN 1092-1 Type A
C C DN 40 PN 63/100
EN 1092-1 Type B2
D A DN 50 PN 16
EN 1092-1 Type A
D B DN 50 PN 25/40
EN 1092-1 Type A
D D DN 50 PN 63
EN 1092-1 Type B2
D E DN 50 PN 100
EN 1092-1 Type B2
1" - 1 1/2" Tri-clamp®
2" Tri-clamp®
DN 65 Varivent®
SENSOR TYPE
A
C
EN 1092-1 Type A
EN 1092-1 Type A
EN 1092-1 Type A
Standard sensor: min -40 °C / max +165 °C (-40 °F / +325 °F)
Low temperature sensor: min -80 °C / max +120 °C (-110 °F / +250 °F) – only available with 9M1-A
ACTUATION LENGTH – specify per cm (0.39") increment
Total insertion length = actuation length + 6 mm (0.25")
9M1 transducers
0 0 3
0 0 5
3 3 0
Minimum 3 cm (1.2") – for metal transducers with NPT connections only
Minimum 5 cm (2") – for all other connections
Maximum 330 cm (130")
0 1 3
0 1 5
3 3 0
Minimum 13 cm (5.1") – for metal transducers with NPT connections only
Mininimum 15 cm (5.9") – for all other connections
Maximum 330 cm (130")
9M2 transducers "A" length
specify "B" length separately (min 8 cm and max 318 cm between "A" and "B")
9 M
complete code for Echotel® transducer
X = product with a specific customer requirement
9
DIMENSIONS IN mm (inches)
102
(4)
102
(4)
113 (4.43) without window
123 (4.85) with window
113 (4.43) without window
123 (4.85) with window
46 (1.8) Typical
Actuation
length
for BSP
connection
6 (0.25)
60 (2.35) Typical
Actuation length
for NPT connection
Actuation length
6 (0.25)
Ø 22,5 (0.88)
961 - Threaded connection
Ø 22,5 (0.88)
961 - Flanged connection
102
(4)
102
(4)
113 (4.43) without window
123 (4.85) with window
113 (4.43) without window
123 (4.85) with window
Actuation length
“B” for BSP
connection
Actuation
length “A”
for BSP
connection
6 (0.25)
46 (1.8) Typical
Actuation length “B”
for NPT connection
Actuation length
“B”
Actuation length “A”
for NPT connection
Ø 22,5 (0.88)
962 - Threaded connection
10
60 (2.35) Typical
Actuation length “A”
6 (0.25)
Ø 22,5 (0.88)
962 - Flanged connection
DIMENSIONS IN mm (inches)
52
(2.05)
58
(2.28)
60
(2.36)
125
(4.92)
Cable entry
109
(4.28)
43°
43° View
35 (1.38)
29 (1.14)
Actuation Length
Ø 22,5 (0.88)
Actuation Length
Ø 22,5 (0.88)
6 (0.25)
6 (0.25)
Tri-Clamp®
46 (1.81)
Actuation Length
Ø 22,5 (0.88)
6 (0.25)
DIN 11851
Varivent®
11
SPECIFICATIONS
Electronics specifications
Description
Input Voltage
Power Consumption
Output
Time delay
Indication
Selftest
Housing material
Automatic
Manual
Approvals ➀
SIL (Safety Integrity Level)
Shock/Vibration
Net weight
Specification
102 - 265 V AC 50/60 Hz or 18 - 32 V DC
< 3 Watt
961: one 5 A DPDT relay,
962: two 5 A SPDT relays
961/962: one 5 A SPDT malfunction relay
0,5 to 45 s adjustable (in addition to transducer response time)
LEDʼs for process alarm status, malfunction (error of transducer, electronics or electrical noise interference) and wet/dry status of transducer (961 only)
Continuously verifies electronics, transducer and noise interference
Via pushbutton for checking alarm output(s) and error output/function.
IP66, cast aluminium, cast stainless steel or deep drawn 304 stainless steel (IP 67)
ATEX II 1/2 G EEx d IIC T6 flameproof enclosure (units with metal transducers)
Overfill prevention TÜV - WHG § 19 / VLAREM II 5.17.7
Other approvals are available, consult factory for more details
Functional safety to SIL 2 in accordance to IEC 61508 – SFF > 90 %.
Full FMEDA report and declaration sheets available at request.
ANSI/ISA-S71.03 Class SA1 (shock), ANSI/ISA-S71.03 Class VC2 (vibration)
Aluminium / Deep drawn 304 SST: 1 kg (2.2 lbs) – electronics only
Cast SST: 2,5 kg (5.5 lbs) – electronics only
➀ Only available with cast aluminium or cast stainless steel housings.
Performance
Description
Response time
Repeatability
Ambient Temperature
Humidity
Electromagnetic Compatibility
Transducer specification
Specification
0,5 s typical
± 2 mm (0.078")
-40 °C to +70 °C (-40 °F to +160 °F)
0-99 %, non-condensing
Meets CE requirements (EN 61326: 1997 + A1 + A2) and NAMUR NE 21
Description
Plastic transducers
Mounting
Threaded (NPT/BSP) – Flanged (ANSI - EN (DIN)) – Hygienic
Material
Actuation length
Process temp. (consult temp/
press. graphs)
Max pressure (consult temp/
press. graphs)
Max viscosity
12
Metal transducers
CPVC
Kynar® (PVDF)
316/316L SST (1.4401/1.4404)
Hastelloy® C (2.4819)
Monel® (2.4360)
From 5 cm up to 330 cm (2" up to 130")
From 3 cm up to 330 cm (1.2" up to 130")
13,8 bar @ +40 °C (200 psi @ +100 °F)
for NPT threaded units
82,8 bar (1200 psi) for Monel transducers
Consult temp/press. graphs for other
materials
-40 °C to +120 °C (-40 °F to +250 °F) – PVDF
-40 °C to +80 °C (-40 °F to +180 °F) – CPVC
-40 °C to +165 °C (-40 °F to +325 °F) – standard
-80 °C to +120 °C (-110 °F to +220 °F) – low
temperature version in 316/316L SST
Flanged models are downrated to the design pressure of the selected flange
10.000 cP
PRESSURE / TEMPERATURE RATINGS
CPVC Transducer Ratings
30
Process pressure (bar)
Process pressure (bar)
Kynar® Transducer Ratings
25
20
15
10
5
0
-40
0
40
80
120
Process temperature (°C)
160
30
25
20
Range with 3/4" NPT
15
10
Range with 150# flange
5
0
-40
Range with PN16 flange
0
40
80
120
Process temperature (°C)
120
Metal Transducer Ratings
80
Process pressure (bar)
40
-40
160
120
80
0
40
80
120
138 bar➀
165
103 bar
316/316L (1.4401/1.4404)➁
Hastelloy® C (2.4819)
Monel® (2.4360)
82,8 bar
40
-40
0
40
80
120
165
Process temperature (°C)
➀ Only applicable to NPT-connections with actuation length = 3 cm
and BSP/ANSI/EN (DIN)-connections with actuation length = 5 cm
➁ For low temperature sensor: from -80 °C up to +120 °C
13
14
15
IMPORTANT
SERVICE POLICY
Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or
replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to
the purchaser, (or owner) other than transportation cost if:
a. Returned within the warranty period; and,
b. The factory inspection finds the cause of the malfunction to be defective material or workmanship.
If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour
and the parts required to rebuild or replace the equipment.
In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the
original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the
control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of
our warranty.
No claims for misapplication, labour, direct or consequential damage will be allowed.
RETURNED MATERIAL PROCEDURE
So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA)
form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is
available through Magnetrolʼs local representative or by contacting the factory. Please supply the following information:
1. Purchaser Name
2. Description of Material
3. Serial Number and Ref Number
4. Desired Action
5. Reason for Return
6. Process details
Any unit that was used in a process must be properly cleaned in accordance with the proper health and safety standards
applicable by the owner, before it is returned to the factory.
A material Safety Data Sheet (MSDS) must be attached at the outside of the transport crate or box.
All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments.
All replacements will be shipped Ex Works.
BULLETIN N°:
EFFECTIVE:
SUPERSEDES:
UNDER RESERVE OF MODIFICATIONS
BE 51-645.5
MAY 2010
April 2008
www.magnetrol.com
BENELUX
FRANCE
Heikensstraat 6, 9240 Zele, België -Belgique
Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected]
DEUTSCHLAND
Alte Ziegelei 2-4, D-51491 Overath
Tel. +49 (0)2204 / 9536-0 • Fax. +49 (0)2204 / 9536-53 • E-Mail: [email protected]
INDIA
C-20 Community Centre, Janakpuri, New Delhi - 110 0058
Tel. +91 (11) 41661840 • Fax +91 (11) 41661843 • E-Mail: [email protected]
ITALIA
Via Arese 12, I-20159 Milano
Tel. +39 02 607.22.98 (R.A.) • Fax. +39 02 668.66.52 • E-Mail: [email protected]
U.A.E.
DAFZA Office 5EA 722 • PO Box 293671 • Dubai
Tel. +971-4-6091735 • Fax +971-4-6091736 • E-Mail: [email protected]
UNITED
KINGDOM
Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL
Tel. +44 (0)1444 871313 • Fax +44 (0)1444 871317 • E-Mail: [email protected]